11_Manufacturing_1-9

It refers to the shape and angles of the cutting tool used in turning operations.

Electro Chemical Machining.

A single point cutting tool.

Electro Chemical Machining (ECM).

A process where sand mixed with thermosetting resin is allowed to contact a heated metal pattern to form a shell.

sin(2v) = sin(2s) * (v/cos(φ - α))

Different types of views of cutting tools.

It is a non-traditional machining method.

About 3.5 mm.

ε̇ = V_s / t_s, where t_s is the thickness of the shear zone.

A process in which molten metal flows by gravity or other force into a mold where it solidifies in the shape of the mold cavity.

Abrasive Jet Machining.

A process where a beam of electrons is magnetically focused on the work piece in a vacuum chamber.

Gating ratio is defined as the ratio of sprue area to runner area to ingate area.

A non-traditional machining method that uses a narrow jet of water directed at high pressure and velocity against the surface of a workpiece.

Dimensional accuracy, smoother surface finish, ability to cast very thin sections, and requires a small amount of sand.

25 microns.

Constant current welding machines.

Gravity or other forces.

h = tan(cot(s) * e * f * C) + C.

MRR is proportional to QD, where Q is the flow rate of abrasives and D is the mean diameter of abrasives.

It utilizes heat from a high-power concentrated laser beam to melt metal interfaces.

19 to 25 kHz.

The sprue is the channel through which molten metal is brought into the parting plane to enter the runners and gates, ultimately reaching the mould cavity.

Expensive patterns, small size castings only, cannot obtain highly complicated shapes, and requires sophisticated equipment.

A narrow jet of water is directed at high pressure and velocity.

1/10th or 10% of the shear plane length.

Constant voltage machines.

Ra = (4 * tan(cot(s) * e * h * f * C) + C) / 4.

It solidifies in the shape of the mold cavity.

2(ab / (a + b)).

Ranging between 4 and 10.

Flow rate of abrasives.

15 to 50 μm.

It is the reverse of electroplating.

The sprue is tapered to gradually reduce the cross section and eliminate the problem of air aspiration.

The relationship between cutting speeds and angles.

Material Removal Rate.

Wear ratio = Volume of metal removed from work / Volume of metal removed from tool.

A process where ceramics are formed around wax patterns to create a casing for molten metal.

Open circuit voltage.

The cutting edge is perpendicular to the direction of cutting velocity.

h = 2 * 8 * f * R.

A specific type of casting process that uses sand as the mold material.

A welding process that uses heat generated by electric current to join metal pieces, capable of welding thicker materials than spot welding.

MRR = (3 AI cm^3)/(vF sec) = (3 EI cm^3)/(F sec)

D / 6.

Very low between the overlapping plates.

Mean diameter of abrasives.

A downward feed force, F.

The work-piece is made the anode.

It indicates that the height of the top gate equals the height of the bottom gate.

It helps in understanding the cutting process and tool engagement.

Different parameters such as pressure, velocity, and nozzle design.

r = ct / c0 = sin(φ) / cos(φ - α).

τ = R c × C.

The maximum rated voltage between open terminals under no loading conditions.

T_o = 1/T_c * (C_n / (C_m + C_t))

Exceptional surface polish, high dimensional precision, ability to cast complicated elements, and compatibility with almost any metal.

The cutting edge is wider than the workpiece width and extends beyond the workpiece on either side.

It produces coalescence over the entire area of abutting surfaces by heat obtained from resistance to electric current.

Ra = 2 * 18 * 3 * f * R.

The die casting alloy is melted in a furnace located within the equipment.

MRR = (3 eq EI cm^3)/(F sec) where eq = (100 F ρ)/(Σ i xi 100 x v and E A)

To facilitate the machining process.

D / 6.

Up to 100,000 A.

Primary wear zone, Secondary wear zone, Tertiary wear zone.

A process where molten metal is poured into an open face die, and a punch applies pressure while the part solidifies.

A high-amperage direct current through an electrolyte.

Straight sprue and tapered sprue.

The magnitude of strain that develops along the shear plane due to machining action.

i c = (1 / R) × V 0 × e^(-t/τ).

Short circuit current.

Tool changing time (in minutes).

The chip generated flows on the rake face of the tool with chip velocity perpendicular to the cutting edge.

Costly patterns and molds, high labor costs, and limited size.

Flash welding uses arc heating instead of resistance heating.

Hot Chamber Die Casting has a higher production capacity due to shorter casting cycles.

It represents the current (I) in terms of applied voltage (V), over voltage (∆V), and resistance (R).

To feed liquid metal to the solidifying casting and compensate for solidification shrinkage.

D / 6.

0.5 to 10 V.

H = I² × R, where I is the current and R is the resistance of the electrolyte in the gap.

A slurry of plaster, water, and various additives.

The wear rate is constant.

The atomic weight of the work material.

To make cavities and hollow projections.

A process by which two materials, usually metals, are permanently joined together by coalescence induced by temperature, pressure, and metallurgical conditions.

V c = 0.72 × V 0.

ϵ = cot(φ) * tan(φ - α).

The maximum rated current required during arc generation.

A welding technique similar to flash welding that uses a rapid discharge of stored electrical energy to create an intense arc for a very short duration.

Rod diameter.

Tooling cost (in Rs. per servicing or replacement).

The cutting forces act along two directions only.

High welding speeds and high deposition rates.

Low melting point alloys.

MRR = A_c * v = w * t_0 * v.

Cooling rate.

To support cores inside the mould cavity.

Carburizing flame.

J = I / A, where A is the cross-sectional area of the electrode.

Risers must solidify after the casting.

At the interface between the two plates being joined.

The freezing ratio, which is the ratio of cooling characteristics of casting to the riser.

A process using artificially composed loam made of brick-clay and sharp sand, restricted to forms that cannot be cast conveniently in other processes.

Wear gradually increases.

H_e = q ρ_e c_e (T_f - T_i), where q is the flow rate, ρ_e is the density, c_e is the specific heat, T_i is the initial temperature, and T_f is the final temperature.

Low voltage and high current.

Core sand should be of higher strength than moulding sand.

Temperature, pressure, and metallurgical conditions.

To obtain power estimates.

A welding process that uses heat from an exothermic reaction between metal oxides and reducing agents to produce coalescence between metals.

Spark energy, calculated as E s = (1/2) × C × V c^2 / cycle.

It illustrates the force relations in orthogonal cutting.

Drooping characteristics to maintain constant current when arc length changes.

A shape factor.

An inexpensive and the simplest type of pattern.

Machining cost (in Rs. per minute).

OCV + SCC = V.

Gas welding.

It has longer casting cycles, resulting in less product capacity.

A_c is the cross-section area of the uncut chip (mm²).

Less than 0.3% carbon.

It can carburize metal.

A represents the atomic weight.

A good riser shape has a long freezing time, meaning a small surface area per unit volume.

To increase the cooling rate of castings.

Resistance seam welding uses wheel-shaped electrodes and the workpiece rolls between them.

It relates cutting speed, time, and tool life.

It is the most widely used furnace for melting cast iron.

x must be greater than 1.

It accounts for all the heat losses in the system.

Electrochemical Machining (ECM).

Vc = Vmaterial + Vtool.

A welding process where an arc is generated between cathode and anode to establish the flow of current.

Clay-free silica sand.

It generates heat by an electric current passing between a consumable electrode and the workpiece through molten slag.

Open circuit voltage (V 0), charging resistance (R), and capacitance (C).

To integrate the gating and runner system with the pattern, improving productivity by eliminating hand cutting.

SF = Length + Width + Thickness.

Reverse polarity.

Shear force.

T_o = 1/T_c * (n / (n - 1))

Oxygen and acetylene.

Aluminum, Copper, Brass, Magnesium, etc.

v = π * D * N, where N is the spindle speed.

Its melting temperature is lower than iron oxide.

About 3000°C.

v stands for valency.

Total solidification time (t_s) = n * (V_B / A), where n = 1.5 to 2.0.

A reservoir of molten metal that allows hot metal to flow back into the mould cavity during solidification.

Circular disc.

V (cutting speed), T (time), n (exponent), C (constant).

A rotating, metal bonded, diamond grit grinding wheel.

It preheats the air blast using flue gases, resulting in higher temperatures than conventional cupolas.

The ratio of the volume of the riser to the volume of the casting.

It relates the weight of a material to current and time.

A box-like structure made of rectangular or circular walls, without a bottom or top.

Laser beam welding < MIG welding < Submerged arc welding < Arc welding.

Vs = Vchip / Vmaterial.

65% to 75% heat is generated at the anode.

Linseed oil, core oil, resins, dextrin, molasses.

Liquid shrinkage occurring during the solidification of the casting.

To prevent contamination of the electrode.

Heat input = b Vl A v (Joule/mm³)

To accelerate the cooling of various regions and promote directional solidification.

Tool regrind cost and tool depreciation per service/replacement.

For intricate castings where withdrawal from the mould is difficult.

Normal to shear force.

Acetylene (C2H2).

P_c = F_c / A, where F_c is the cutting force and A is the cross-section area of the undeformed chip.

Molten metal is introduced into a rotating mold and held against the mold wall by centrifugal force until solidified.

To cut metals that are difficult to cut by oxy-fuel cutting, such as cast iron and stainless steel.

It affects the current flow and efficiency of the machining process.

Oxy-fuel welding (fusion welding).

T_sp : T_cy : T_cu = 1 : 0.763 : 0.649.

A replica of the object to be made, with modifications.

It is changed to a metal oxide, which is then ground away by the abrasives.

Sliding of the tool along the machined surface and temperature rise.

Electric Arc Furnace.

5.08 cm.

Constants used in the equation for calculating x.

96,500 coulombs.

Mostly cast iron, although wood is also used sometimes.

Flux coating, Flux granules, CO2, Vacuum.

Vc = Vchip / Vtool.

By proper feeding of liquid metal and placing risers in the mold.

Core oil (1%) and water (2.5 to 6%).

When DC is used and the work is positive (the anode of the circuit).

1. Deoxidizing agent 2. Arc stabilizing agent 3. Slag forming agent.

High-heat-capacity, high-thermal-conductivity materials.

The number of minutes within a 10-minute period a welder can safely produce a particular welding current.

Two halves of the pattern along with gating and riser systems, attached to plates with alignment pins.

Labour cost and overhead cost per minute.

About 3300° C in the oxidizing flame.

F_c.

Mechanical properties of centrifugally cast jobs are better compared to other processes.

Flank wear, crater wear, and chipping off of the cutting edge.